Simulation – Sorting Center

Why simulate a waste sorting center?

Managing a sorting center relies on many interconnected variables: sorting rates, incoming volumes, equipment availability, team schedules. Operations managers traditionally rely on field experience and spreadsheets to make their decisions. But this approach quickly reaches its limits when facing the growing complexity of modern facilities.

Collection peaks, unexpected breakdowns, seasonal volume variations or new regulatory constraints make it difficult to anticipate bottlenecks and optimally plan resources. This is where the digital twin comes in: a virtual replica of your sorting center, capable of simulating and optimizing every parameter.

How does our sorting center simulator work?

We have just completed an advanced simulator, developed in AnyLogic, which faithfully reproduces the operation of a waste sorting center: incoming flows by trucks or barges, configurable pre-sorting zones, manual sorting line, automated management of full skips, and internal truck circulation.

Incoming flow and pre-sorting zone modeling

The model integrates different reception modes: collection trucks and river barges. The pre-sorting zones are fully configurable: equipment rates, recovery and rejection rates, operating hours, capacities — all managed via an external database.

Configurable manual sorting line

The manual sorting line is modeled with a high level of detail: adjustable conveyor speed, sorting rate by material, breakdown management, and automatic correlation between conveyor speed and sorting efficiency. Sorted materials fill skips with automatic emptying triggered.

Intelligent truck and skip management

Internal truck routing follows intelligent logic: priority to the zone connected to the sorting line, automatic redirection to other zones in case of saturation, switchover to the pit if all zones are occupied.

What scenarios can you test?

With fully customizable parameters (sorting line rates, recovery rates, processing times, working hours, number of available excavators, number of construction barges in reception…), the simulator allows you to test various scenarios and anticipate the effects of a poor transport plan or congestion.

Transport plan simulation: detection of the limits of a system without appointments with municipalities (peaks, congestion, underuse, performance drops). Testing scenarios with smoothed volumes and adjusted schedules.

Algorithmic optimization: once key parameters are identified, the model can be used intensively. Optimization algorithms determine optimal settings according to your criteria: maximize recovery, reduce waiting times, balance the load between zones.

Data is driven by external databases, simulations are launched using interactive sliders, and each scenario generates operational, economic and environmental indicators.

A strategic tool for your teams

This model is a genuine working tool. It tests hypotheses, reveals performance levers, identifies key parameters. You can then build a realistic strategy, aligned with the model. If your teams are involved from the start, implementation will be smooth and shared.

This simulator is a strategic digital twin, a decision-support tool and an industrial optimization lever for your sorting center.

Want to optimize your sorting center?

Lean Art supports industrial companies and sorting center operators in their optimization approach through simulation. Contact us for a demonstration and discover how a digital twin can transform your decision-making.